Manufacturing methods of a coil member and a coil assembly of a rotary electric machine and manufacturing apparatus for said coil member

ABSTRACT

A manufacturing method includes a step of setting prescribed dimensions L and p, a wire feeding step of feeding a wire on a turning base surface by the dimension L, a turning step of turning the wire on the turning base surface to thereby form a first turning portion, a straight first portion, a second turning portion and a straight second portion, and a pushing step of pushing the straight first portion or the straight second portion so that it goes away from the turning base surface by the dimension p. A manufacturing apparatus that executes the above steps is also disclosed.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a manufacturing method of a coilmember of a rotary electric machine such as a vehicular AC generatorthat is mounted on a car, a truck, or the like, a manufacturing methodof a coil assembly that is an assembly of coil members each being theabove one, and a manufacturing apparatus for the above coil member.

[0003] 2. Description of the Related Art

[0004] The present assignee proposed a technique for increasing themass-productivity of the above-kind of coil member of a rotary electricmachine and coil assembly in U.S. of Pat. No. 6,376,961 (in particular,line 58 of column 11 to line 12 of column 12, and FIG. 8). In thisrelated art technique, a coil assembly of a rotary electric machine hasa plurality of coil combinations each being a combination of two coilmembers. Each coil member is manufactured by turning a wirecontinuously. This technique can provide higher mass-productivity thanin a case that many conductor segments are joined to each other.

[0005] This related art reference proposes a manufacturing method inwhich a plurality of wires are wound simultaneously in spiral form byusing a pair of plate-like winding cores shown in FIG. 8 of thereference. Each plate-like winding core has, on the outer surface, aplurality of projections for restraining a plurality of wires. Thismethod using such plate-like winding cores can form a plurality of(e.g., 12) coil members simultaneously by winding the same number ofwires on the pair of plate-like winding cores and folding thosesequentially.

[0006] However, in this related art technique, the projections that areprovided on the outer surface of each of the plate-like winding coreshave a fixed interval. Therefore, it is difficult to change the pitch ofeach of a plurality of coil members, that is, the interval between twoadjoining straight portions. To adjust the length of straight portions,it is necessary to prepare plural pairs of plate-like winding coreshaving different widths and replace one pair with another; the length ofstraight portions cannot be adjusted easily either.

SUMMARY OF THE INVENTION

[0007] An object of the present invention is to provide an improvedmanufacturing method of a coil member of a rotary electric machine whichcan easily adjust the pitch and the length of straight portions of thecoil member.

[0008] Another object of the invention is to provide an improvedmanufacturing method of a coil assembly of a rotary electric machinewhich can easily adjust the pitch and the length of straight portions ofeach of coil members of the coil assembly.

[0009] A further object of the invention is to provide an improvedmanufacturing apparatus of a coil member of a rotary electric machinewhich can easily adjust the pitch and the length of straight portions ofthe coil member.

[0010] The invention provides a manufacturing method of a coil member ofa rotary electric machine including a winding step of forming a firstturning portion, a straight portion, and a second turning portion in atleast one wire. The winding step includes next steps: a step of settingprescribed dimensions L and p; a first turning step of forming the firstturning portion by turning the wire on a turning base surface; a wirefeeding step of advancing the wire by the prescribed dimension L afterthe first turning step; a second turning step of turning, after the wirefeeding step, the wire on the turning base surface in the same directionas the wire was turned in forming the first turning portion, to therebyform the second turning portion and form the straight portion betweenthe first turning portion and the second turning portion; and a pushingstep of pushing, after the second turning step, the straight portion sothat the straight portion goes away from the turning base surface by theprescribed dimension p.

[0011] According to this manufacturing method of the coil member of therotary electric machine, the prescribed dimensions L and p can bechanged easily and hence a coil member can be manufactured while thelength and the pitch of straight portions of the coil member are changedeasily when necessary.

[0012] The invention also provides a manufacturing method of a coilassembly of a rotary electric machine in which the coil assemblyincludes a plurality of coil members each of which is formed by awinding step of winding a wire so as to form a plurality of firstportions, a plurality of second portions, a plurality of first turningportions each of which connects one of the first portions and one of thesecond portions that is located on one side of and adjacent to the oneof first portions, and a plurality of second turning portions each ofwhich connects one of the first portions and one of the second portionsthat is located on the other side of and adjacent to the one of firstportions. The winding step includes next steps: a step of settingprescribed dimensions L and p; a first wire feeding step of feeding thewire to thereby set the length L for one of the first portions based onthe prescribed length L; a first turning step of turning, after thefirst wire feeding step, the wire on a turning base surface to therebyform one of the first turning portions and one of the first straightportions. The winding step also includes next steps: a first pushingstep of pushing, after the first turning step, the one of first portionsso that the one of first portion goes away from the turning base surfaceby the prescribed dimension p; a second wire feeding step of feeding,after the first pushing step, the wire to thereby set the length L forone of the second portions based on the prescribed length L; a secondturning step of turning, after the second wire feeding step, the wire onthe turning base surface in the same direction as the wire was turned informing the one of first turning portions, to thereby form one of thesecond turning portions and form one of the second portions between theone of first turning portions and the one of second turning portions;and a second pushing step of pushing, after the second turning step, theone of second portions so that the one of second portions goes away fromthe turning base surface by the prescribed dimension p.

[0013] According to this manufacturing method of the coil assembly ofthe rotary electric machine, the prescribed dimensions L and p can bechanged easily and hence a coil assembly can be manufactured while thelength and the pitch of first and second portions of each coil memberare changed when necessary.

[0014] The invention further provides a manufacturing apparatus for acoil member of a rotary electric machine having first turning portions,straight portions, and second turning portions. The manufacturingapparatus includes a rotary plate, a first motor, a central shaft, ashaping roller, a wire feed mechanism, a second motor, a first settingelement, a pushing member, a third motor and a second setting member.The rotary plate has a turning base surface on which winding of a wireis performed. The first motor rotates the rotary plate intermittentlyabout an axis thereof. The central shaft is provided perpendicularly tothe turning base surface on the axis of the rotary plate. The shapingroller is attached to the rotary plate perpendicularly to the turningbase surface and the shaping roller is opposed to the central shaft witha shaping gap formed in between, and rotates around the central shaft.The wire feed mechanism feeds the wire through the shaping gap. Thesecond motor drives the wire feed mechanism intermittently. The firstsetting element sets a dimension L of the wire feed by the driving ofthe second motor. The pushing member is movable along the axis of therotary plate. The third motor drives the pushing member intermittently.The second setting element sets a dimension p of a push of the pushingmember by the driving of the third motor. The manufacturing apparatusexecutes next steps. One of the steps is causing the first motor to turnthe wire on the turning base surface to thereby form one of the firstturning portions. Another one of the steps is causing, after forming theone of first turning portions, the second motor to advance the wire bythe dimension L that is set by the first setting element. Another one ofthe steps is causing, after advancing the wire, the first motor to turnthe wire on the turning base surface in the same direction as the wirewas turned in forming the one of first turning portions, to thereby formone of the second turning portions and form one of the straight portionsbetween the one of first turning portions and the one of second turningportions. Still another one of the steps causing, after forming the oneof second turning portions, the third motor to move the pushing memberso as to push the one of straight portions so that the one of straightportion goes away from the turning base surface by the dimension p.

[0015] According to this manufacturing apparatus for the coil member ofthe rotary electric machine, the prescribed dimensions L and p can bechanged easily and hence a coil member can be manufactured while thelength and the pitch of straight portions of the coil member are changedeasily when necessary.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a development of a coil assembly of a rotary electricmachine that is manufactured according to the present invention;

[0017]FIG. 2 is a development of part of a coil member of a rotaryelectric machine that is manufactured according to the presentinvention;

[0018]FIG. 3 is a development of part of one coil combination of arotary electric machine that is manufactured according to the presentinvention;

[0019] FIGS. 4(a) and 4(b) are a plan view and a front view,respectively, showing the main part of a coil manufacturing apparatusthat is used in a manufacture method of a coil member of a rotaryelectric machine according to the invention;

[0020] FIGS. 5(a) and 5(b) to FIGS. 22(a) and 22(b) illustraterespective steps of a winding step of a first embodiment relating to amanufacturing method of a coil member of a rotary electric machineaccording to the invention in which FIGS. 5(a), 6(a), . . . , 22(a) areplan views and FIGS. 5(b), 6(b), . . . , 22(b) are front views;

[0021]FIG. 23 is a plan view showing an intermediate state of thewinding step of the first embodiment relating to the manufacturingmethod of a coil member of a rotary electric machine according to theinvention;

[0022] FIGS. 24(a) and 24(b) are a plan view and a front view,respectively, of a coil member obtained after completion of execution ofthe winding step of the first embodiment;

[0023] FIGS. 25(a) and 25(b) to FIGS. 30(a) and 30(b) illustraterespective steps of a weaving step of a second embodiment relating to amanufacturing method of a coil assembly of a rotary electric machineaccording to the invention in which FIGS. 25(a), 26(a), . . . , 30(a)are plan views and FIGS. 25(b), 26(b), . . . , 30(b) are front views;

[0024]FIG. 31 is a plan view of a coil assembly that is obtained aftercompletion of execution of the weaving step of the second embodiment;

[0025] FIGS. 32(A)-32(C) illustrate a pressing step and a displacingstep of the second embodiment relating to the manufacturing method of acoil assembly of a rotary electric machine according to the invention;

[0026]FIGS. 33 and 34 are a plan view and an explanatory diagram,respectively, illustrating a displacing step of the second embodimentrelating to the manufacturing method of a coil assembly of a rotaryelectric machine according to the invention;

[0027]FIG. 35 is a plan view illustrating a weaving step of a thirdembodiment relating to the manufacturing method of a coil assembly of arotary electric machine according to the invention;

[0028]FIG. 36 is a plan view illustrating a weaving step of a fourthembodiment relating to the manufacturing method of a coil assembly of arotary electric machine according to the invention;

[0029]FIG. 37 is a plan view of another coil assembly obtained aftercompletion of execution of a weaving step according to the invention;

[0030]FIG. 38 is a plan view illustrating a weaving step of a fifthembodiment relating to the manufacturing method of a coil assembly of arotary electric machine according to the invention;

[0031]FIG. 39 is a plan view of another coil assembly obtained aftercompletion of execution of a weaving step according to the invention;

[0032]FIG. 40 is a front view showing the configuration of a windingmachine (sixth embodiment) of a coil member of a rotary electric machineaccording to the invention;

[0033]FIG. 41 is a sectional view taken along line A-A in FIG. 40; and

[0034]FIG. 42 is a sectional view of a rotary electric machine using acoil assembly according to the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] [Coil Member and Coil Assembly of Rotary Electric Machine]

[0036] A coil member and a coil assembly of a rotary electric machinethat are manufactured according to the present invention will bedescribed before description of embodiments of manufacturing methods ofa coil member and a coil assembly of a rotary electric machine and amanufacturing apparatus of a coil member of a rotary electric machineaccording to the invention.

[0037]FIG. 1 is a development of a coil assembly of a rotary electricmachine that is manufactured by the manufacturing method of coilassembly of a rotary electric machine according to the invention. FIG. 2is a perspective view of part of one coil member of the coil assemblyshown in FIG. 1. FIG. 3 is a perspective view of part of one coilcombination of the coil assembly shown in FIG. 1.

[0038] The coil assembly 10 of FIG. 1 has a plurality of coilcombinations 12, specifically, six coil combinations 12A-12F. Each ofthe coil combinations 12A-12F extends in spiral form continuously fromthe left end to the right end in FIG. 1. Each coil combination 12 is acombination of a plurality of coil members 15, specifically, two coilmembers 151 and 152. As shown in FIG. 2, each coil member 15 is formedby winding a single insulated wire in spiral form. The coil assembly 10of FIG. 1 has twelve coil members 15 in total because the coil assembly10 has the six coil combinations 12 and each coil combination 12 has thetwo coil members 15. The wire of the coil members 15 is a long member inwhich a conductive material such as copper is coated with an insulativematerial; for example, a conductive material having a circularcross-section is coated with an enamel coating. Alternatively, a coatedwire having a rectangular cross-section may be used.

[0039] In the developed state shown in FIG. 2, each coil member 15 has aplurality of portions 15A that are located in a first plane, a pluralityof second portions 15B that are located in a second plane, a pluralityof first turning portions 15C, and a plurality of second turningportions 15D. Each coil member 15 is formed by winding a single wire soas to form the portions 15A-15D that are continuous with each other. Thefirst plane where the plurality of first portions 15A exist and thesecond plane where the plurality of second portions 15B exist areparallel with and opposed to each other with a very small gap interposedin between. Each of the first portions 15A has a first parallel straightportion 15 a 1 (the first parallel straight portions 15 a 1 are parallelwith each other) and two inclined portions 15 a 2 and 15 a 3 that areinclined from the first parallel straight portion 15 a 1. The inclinedportions 15 a 2 and 15 a 3 are located above and below the firstparallel straight portion 15 a 1, respectively, in FIG. 2. Let L1 and L2represent the lengths of the first parallel straight portion 15 a 1 andeach of the two inclined portions 15 a 2 and 15 a 3; then, the length Lof the first portion 15A is given by L=L1 and 2L2.

[0040] Each of the second folded straight portions 15B has a secondparallel straight portion 15 b 1 (the second parallel straight portions15 b 1 are parallel with each other) and two inclined portions 15 b 2and 15 b 3 that are inclined from the second parallel straight portion15 b 1. The inclined portions 15 b 2 and 15 b 3 are located above andbelow the second parallel straight portion 15 b 1, respectively, in FIG.2. The length of the second parallel straight portion 15 b 1 is the sameas that of the first parallel straight portion 15 a 1, that is, L1. Thelength of each of the inclined portions 15 b 2 add 15 b 3 is the same asthat of each of the inclined portions 15 a 2 add 15 a 3, that is, L2.Therefore, the length of the second portion 15B is equal to the length Lof the first portion 15A.

[0041] The interval between two adjoining first parallel straightportions 15 a 1 is equal to that between two adjoining second parallelstraight portions 15 b 1 (represented by 2P in FIG. 2). Each secondparallel straight portion 15 b 1 is parallel with each first parallelstraight portion 15 a 1 and is located right at the center of theinterval between the two parallel straight portions 15 b 1 adjacent tothe second parallel straight portion 15 a 1. As a result, the intervalbetween a first parallel straight portion 15 a 1 and a second parallelstraight portion 15 b 1 adjacent to each other is equal to P.

[0042] In FIG. 2, the first turning portions 15C are located above thefirst portions 15A and the second portions 15B, and the second turningportions 15D are located below the first portions 15A and the secondportions 15B. Each first turning portion 15C connects a first portion15A (in the first plane) and a second portion 15B (in the second plane)that is located on one side of and adjacent to that first portion 15A.More specifically, each first turning portion 15C connects an inclinedportion 15 a 2 (in the first plane) that is inclined from a firstparallel straight portion 15 a 1 and an inclined portion 15 b 2 (in thesecond plane) that is inclined from a second parallel straight portion15 b 1 that is located on one side of and adjacent to that firstparallel straight portion 15 a 1.

[0043] Each second turning portion 15D connects a first portion 15A (inthe first plane) and a second portion 15B (in the second plane) that islocated on the other side of and adjacent to that first portion 15A.More specifically, each second turning portion 15D connects an inclinedportion 15 a 3 (in the first plane) that is inclined from a firstparallel straight portion 15 a 1 and an inclined portion 15 b 3 (in thesecond plane) that is inclined from a second parallel straight portion15 b 1 that is located on the other side of and adjacent to that firstparallel straight portion 15 a 1.

[0044] Each coil combination 12, that is, each of the coil combinations12A-12F that constitute the coil assembly 10 shown in FIG. 1, isconfigured as shown in FIG. 3. Naturally, FIG. 3 also shows a developedstate. Each coil combination 12 is a combination of two coil members 151and 152. In the coil combination 12 that is shown in FIG. 3 in adeveloped state, the second parallel straight portions 15 b 1 of thecoil member 152 contact, from below, the respective first parallelstraight portions 15 a 1 of the coil member 151, and the first parallelstraight portions 15 a 1 of the coil member 152 contact, from above, therespective second parallel straight portions 15 b 1 of the coil member151.

[0045] The coil assembly 10 of FIG. 1 is placed in a plurality of slotsof the inner circumferential surface of a cylindrical stator iron coreat prescribed intervals. The coil assembly 10 also assumes a cylindricalshape as a whole in a state that it is attached to the stator iron core;FIG. 1 shows the coil assembly 10 as developed on a plane. In a statethat the coil member 10 is attached to the stator iron core, a firstparallel straight portion 15 a 1 of the coil member 151 is inserted in aslot and a second parallel straight portion 15 b 1 of the coil member152 is inserted in the same slot so as to contact that first parallelstraight portion 15 a 1 from below. A second parallel straight portion15 bl of the coil member 151 is inserted in another slot that is distantfrom the former slot by the pitch P and a first parallel straightportion 15 a 1 and a first parallel straight portion 15 a 1 of the coilmember 152 is inserted in the same slot so as to contact that secondparallel straight portion 15 b 1 from above.

[0046] [Embodiment Relating to Manufacturing Method of Coil Member 15 ofRotary Electric Machine]

[0047] Embodiment 1

[0048] A first embodiment relating to the manufacturing method of a coilmember 15 of a rotary electric machine according to the invention willbe hereinafter described.

[0049] In the manufacturing method of a coil assembly 10 according tothe invention, a winding step of forming coil members 15, a weavingstep, a pressing step, a displacing step, and an inserting step areexecuted in this order. Since the weaving step and the following stepsconstitute a manufacturing method of a coil assembly 10 using coilmembers 15, firstly, the first embodiment relating to the manufacturingmethod of a coil member 15 according to the invention that is mainly thewinding step of forming a coil member 15 will be described and then anembodiment relating to the manufacturing method of a coil assembly 10using resulting coil members 15 will be described.

[0050] In the manufacturing method of the coil assembly 10, the firstand second portions 15A, 15B are folded to have the parallel straightportions 15 a 1, 15 b 1 and inclined portions 15 a 2, 15 a 3 and 15 b 2,15 b 3 shown in FIG. 3 by displacing at the displacing step. Before thedisplacing, the first and second portions 15A and 15B are not folded andthe first and second portions 15A, 15 b 1 are straight portionsincluding portions 15 a 1, 15 b 1 and portions 15 a 2, 15 a 3, 15 b 2,15 b 3 that will be folded. Then the first portion 15A and the secondportion 15B are so called as the straight first portion 15A and thestraight second portion 15B before their displacing.

[0051] <Main Configuration of Winding Machine Used>

[0052] FIGS. 4A(a) and 4(b) are a plan view and a front view,respectively, showing the main configuration of a winding machine 20that is used in the first embodiment. As shown in FIGS. 4(a) and 4(b),the winding machine 20 has a turning mechanism 30, a wire feed mechanism50, and a pushing mechanism 60 and winds a wire 17 in spiral form.

[0053] The turning mechanism 30 has a rotary plate 31, a central shaft33, and a shaping roller 35. The turning mechanism 30 has a rotationaldriving mechanism 37 for driving the rotary plate 31 rotationally. Therotary plate 31 is rotated intermittently about its axis O-O indirections indicated by arrows A1 and A2. The rotary plate 31 iscircular, for example, and its one major surface is a circular rotarysurface 32, which serves as a turning base surface for shaping the wire17 in spiral form. The central shaft 33 has the axis O-O as its axis.The central shaft 33 is directly attached to the rotary plate 31 ordisposed so as to have the axis O-O as its axis when it is separate fromthe rotary plate 31. The central shaft 33 has a circular cross-sectionhaving a diameter d1.

[0054] The turning mechanism 30 has a rotary plate moving mechanism 39that reciprocates the rotary plate 31 along its axis O-O. The rotaryplate 31 is driven so as to reciprocate intermittently along its axisO-O in directions indicated by arrows B1 and B2.

[0055] The shaping roller 35 is placed on the turning base surface 32and attached to the rotary plate 31, and hence rotates together with therotary plate 31. The shaping roller 35 has a circular cross-section thatis larger in diameter than the circular cross-section of the centralshaft 33, and forms a shaping gap 36 with the central shaft 33. Thedimension of the shaping gap 36 in the radial direction of the rotaryshaft 31 is equal to the diameter d of the wire 17 plus a small margin.The margin is so set as to enable smooth insertion of the wire 17 intothe shaping gap 36.

[0056] The wire feed mechanism 50 has a pair of feed rollers 51 and 52,at least one of which is an elastic roller. The feed rollers 51 and 52feed the wire 17 intermittently in a direction indicated by arrow Ctoward the shaping gap 36 while holding the wire 17 elastically inbetween.

[0057] The pushing mechanism 60 has a pushing member 61 and areciprocative driving mechanism 62 therefor. The reciprocative drivingmechanism 62, which is to push the wire 17 along the axis so O-O of therotary plate 31 so as to go away from the turning base surface 32 forforming straight first portions 15A and straight second portions 15B ofa coil member 15 that is wound in spiral form, drives the pushing member61 so that it is reciprocated intermittently along the axis O-O of therotary plate 31 in directions indicated by arrows D1 and D2. The pushingmember 61 is disposed very close to the rotary plate 31 immediately overthat part of the wire 17 which extends between the shaping gap 36 andthe wire feed mechanism 50.

[0058] The winding machine 20 of FIGS. 4(a) and 4(b) further has settingelements 23 and 25 for setting prescribed dimensions L and p. The firstsetting element 23 is to set, in the wire feed mechanism 50 that isdriven intermittently, a feed length L of the wire 17 at the time ofeach feed. The setting element 25 is to set, for the pushing member 61,its push length p. The wire feed length L is equal to the length of eachof the straight first portion 15A and the straight second portion 15B ofthe coil member 15 shown in FIG. 2, that is, the sum of the length L1 ofeach of the first parallel straight portion 15 a 1 and the secondparallel straight portion 15 b 1 and two times the length L2 of each ofthe inclined portions 15 a 2, 15 a 3, 15 b 2, and 15 b 3. The pushlength p determines the pitch P between the first parallel straightportion 15 a 1 and the second parallel straight portion 15 b 1, and isset equal to 2P, for example.

[0059] <Winding Step>

[0060] FIGS. 5(a) and 5(b) to FIGS. 22(a) and 22(b) show, in order,steps of the winding step of forming a coil member 15 according to theinvention. The winding step of forming a coil member 15 will bedescribed below in detail with reference to those drawings. FIGS. 5(a),6(a), . . . , 22(a) are plan views and FIGS. 5(b), 6(b), . . . , 22(b)are front views. In this winding step, a coil member 15 as shown in FIG.24 is manufactured. FIG. 31 shows a coil assembly obtained aftercompletion of execution of a weaving step on a plurality of coil members15. The coil assembly shown in FIG. 31 as subjected to the weaving isthen subjected to a pressing step and a displacing step, whereby a coilassembly 10 as shown in FIG. 1 is formed, which is inserted into theslots of an iron core.

[0061] (1) First Step (Wire Feeding Step; FIGS. 5(a) and 5(b) and FIGS.6(a) and 6(b))

[0062] In a first step that is a first wire feeding step, a portionhaving the length L is set for a straight first portion 15A. In thisstep, the rotary plate 31 and the pushing member 61 of the windingmachine 20 stand still. In this state, the wire feed mechanism 50 isdriven, whereby the wire 17 is supplied to the shaping gap 36 asindicated by arrow C. The contact point of the feed rollers 51 and 52and the shaping gap 36 lie in plane E-E. It is assumed that the wire 17is supplied horizontally from the feed mechanism 50 toward the shapinggap 36 so as to trace a wire supply line that lies in plane E-E. FIGS.6(a) and 6(b) show a state that the tip of the wire 17 has advancedleftward by the length L from the shaping gap 36, whereby a portionhaving the length L is set for the straight first portion 15A. The feedof the wire 17 by the feed mechanism 50 is suspended once the state ofFIGS. 6(a) and 6(b) is reached. FIGS. 5(a) and 5(b) show a halfway statebefore the state of FIGS. 6(b) and 6(b). In this first step, the shapingroller 35 is located right under the central shaft 33 and the centeraxis of the shaping roller 35 is located right under the axis O-O (inthe vertical direction).

[0063] (2) Second Step (Turning Step; FIGS. 7(a) and 7(b) and FIGS. 8(a)and 8(b))

[0064] A second step is a turning step of bending the wire 17, that is,a step of forming one straight first portion 15A and one first turningportion 15C in the wire 17. In this step, the rotation of the wire feedmechanism 50 is suspended and the wire 17 is gripped by the feed rollers51 and 52 being sandwiched between them. The rotary plate 31 is rotatedin a direction indicated by arrow A1. As a result, as the shaping roller36 rotates, that portion of the wire 17 which projects from the shapinggap 36 is bent along the outer circumferential surface of the centralshaft 33 on the turning surface 32. FIGS. 7(a) and 7(b) show a statethat the rotary plate 31 has been rotated by 90° from the position ofFIGS. 6(a) and 6(b) and approximately a half of one turning portion 15Chas been formed around the central shaft 33.

[0065] Between the state of FIGS. 6(a) and 6(b) and the state of FIGS.7(a) and 7(b), the rotary plate 31 is moved along its axis O-O in adirection indicated by arrow B1, whereby the angle of the turningportion 15C is adjusted.

[0066] In the second step, the pushing member 60 still stands still.

[0067] In the second step, between the state of FIGS. 7(a) and 7(b) anda state of FIGS. 8(a) and 8(b), the rotary plate 31 is further rotatedby 90° in the direction indicated by arrow A1. In the state of FIGS.8(a) and 8(b), the rotary plate 31 has been rotated by 180° from thestate of FIGS. 6(a) and 6(b); the shaping roller 35 is located rightover the central shaft 33, that portion of the wire 17 which projectsfrom the shaping gap 36 extends horizontally in plane F-F, and the tipof the wire 17 is directed rightward. Plane F-F is parallel with planeE-E and is higher than plane E-E by a dimension that is equal to thediameter d1 of the central shaft 33. One complete turning portion 15C isformed as a result of the 180°-turn of the wire 17. The inner diameterof the turning portion 15C is approximately equal to the diameter d1 ofthe central shaft 33. One straight first portion 15A is formed betweenthe tip of the wire 17 and the turning portion 15C. The straight firstportion 15A and the turning portion 15C correspond to the left endportion of the coil member 15 of FIG. 2. However, since the wire 17 hasnot been subjected to the displacing step yet, a first parallel straightportion 15 a 1 and inclined portions 15 a 2 and 15 a 3 have not beenformed yet and hence the straight first portion 15A is still straight.The rotation of the rotary plate 31 is suspended once the state of FIGS.8(a) and 8(b) is reached. Between the state of FIGS. 7(a) and 7(b) andthe state of FIGS. 8(a) and 8(b), the rotary plate 31 is returned alongits axis O-O in a direction indicated by arrow B2 that is opposite tothe direction indicated by arrow B1.

[0068] In the second step, a half turn of the intended coil member 15 isformed that includes the straight first portion 15A that exists in planeF-F and the first turning portion 15C.

[0069] (3) Third Step (Pushing Step; FIGS. 9(a) and 9(b) and FIGS. 10(a)and 10(b))

[0070] A third step is a step of pushing the straight first portion 15A.In this pushing step, after the half turn has been formed in the secondstep, the pushing member 61 is moved along the axis O-O in a directionindicated by arrow D1, whereby the one straight first portion 15A ispushed in plane F-F so as to go away from the turning base surface 32.FIGS. 9(a) and 9(b) show a state that the rotary plate 31 stands still,the feed of the wire 17 by the feed mechanism 50 is suspended, and thewire 17 is gripped by the feed rollers 51 and 52 being sandwiched inbetween. In this state, the pushing member 61 is moved along the axisO-O in the direction indicated by arrow D1, whereby the one straightfirst portion 15A is pushed by the prescribed dimension p so as to goaway from the turning base surface 32. Between the state of FIGS. 9(a)and 9(b) and a state of FIGS. 10(a) and 10(b), the pushing member 61 isreturned to the original position in a direction indicated by arrow D2that is opposite to the direction indicated by arrow D1. Further,between the state of FIGS. 9(a) and 9(b) and the state of FIGS. 10(a)and 10(b), the rotary plate 31 is rotated in a direction indicated byarrow A2 that is opposite to the direction indicated by arrow A1 so thatthe shaping roller 35 returns to the position right under the centralshaft 33.

[0071] (4) Fourth Step (Wire Feeding Step; FIGS. 11(a) and 11(b) andFIGS. 12(a) and 12(b))

[0072] A fourth step is a second wire feeding step which is the samewire feeding step as the first step is. The individual components of thewinding machine 20 shown in FIGS. 4(a) and 4(b) are moved in the samemanner as in the first step. In the fourth step, a portion having theprescribed length L is set for a straight second portion 15B in planeE-E between the one turning portion 15C and the next turning portion15D. In the fourth step, the rotary plate 31 and the pushing member 61stand still and the wire 17 is fed by the wire feed mechanism 50. FIGS.11(a) and 11(b) show a halfway state of an operation that the wire 17 isfed in the direction indicated by arrow C in plane E-E. Then, the wire17 is further fed by the wire feed mechanism 50 until a state of FIGS.12(a) and 12(b) is reached so as to be fed by the length L from thestate of FIGS. 10(a) and 10(b). In the state of FIGS. 12(a) and 12(b),in plane E-E, a portion having the length L is set between the turningportion 15C of the wire 17 and the shaping gap 36. Once the state ofFIGS. 12(a) and 12(b) is reached, the feed of the wire 17 by the wirefeed mechanism 50 is suspended.

[0073] (5) Fifth Step (Turning Step; FIGS. 13(a) and 13(b) and FIGS.14(a) and 14(b))

[0074] In a fifth step that is a turning step, the individual componentsof the winding machine 20 are moved in the same manner as in the secondstep, whereby the next turning portion 15D is formed. In the fifth step,the feed of the wire 17 by the wire feed mechanism 50 is suspended and,instead, the rotary plate 31 is rotated again in the direction indicatedby arrow A1. FIGS. 13(a) and 13(b) show a state that the rotary plate 31has been rotated in the direction indicated by arrow A1 by 90° from thestate of FIGS. 12(a) and 12(b), and FIGS. 14(a) and 14(b) show a statethat the rotary plate 31 has been rotated further in the directionindicated by arrow A1 by 90° from the state of FIGS. 13(a) and 13(b).The rotary plate 31 is rotated together with the shaping roller 35 inthe state that that portion of the wire 17 which has projected by thelength L from the shaping gap 36 in the fourth step is sandwichedbetween the central shaft 33 and the shaping roller 35, whereby the nextturning portion 15D is formed at a position that is distant from theturning portion 15C by the length L. In the state of FIGS. 14(a) and14(b), the first portion 15A is located in plane E-E and one straightsecond portion 15B is formed between the turning portions 15C and 15D inplane F-F. The inner diameter of the turning portion 15D isapproximately equal to the diameter d1 of the central shaft 33.

[0075] As a result of the execution of the above fourth and fifth steps,the next half turn of the intended coil member 15 including the straightsecond portion 15B and the second turning portion 15D is formed. As aresult of the execution of the above first to fifth steps, one turn ofthe intended coil member 15 including the straight first portion 15A,the turning portion 15C, the straight second portion 15B, and theturning portion 15D is formed in the wire 17.

[0076] (6) Sixth Step (Pushing Step; FIGS. 15(a) and 15(b) and FIGS.16(a) and 16(b))

[0077] A sixth step is a pressing step. The individual components of thewinding machine 20 are moved in the same manner as in the third stepshown in FIGS. 9(a) and 9(b) and FIGS. 10(a) and 10(b). In the sixthstep, after the next half turn of the intended coil member 15 has beenformed in the fifth step, the pushing member 61 is moved again in thedirection indicated by arrow D1, whereby the one second portion 15B thathas been formed in the fifth step is pushed in plane F-F by theprescribed dimension p so as to go away from the turning base surface32. The pushing member 61 is moved in the direction indicated by arrowD1 between the state of FIGS. 14(a) and 14(b) and the state of FIGS.15(a) and 15(b), and is then moved in the direction indicated by arrowD2 that is opposite to the direction indicated by arrow D1 and therebyreturned to the original position between the state of FIGS. 15(a) and15(b) and the state of FIGS. 16(a) and 16(b). In the sixth step, thefeed of the wire 17 by the feed mechanism 50 is suspended. On the otherhand, the rotation of the rotary plate 31 is suspended between the stateof FIGS. 14(a) and 14(b) and the state of FIGS. 15(a) and 15(b) and isreturned in the direction indicated by arrow A2 that is opposite to thedirection indicated by arrow A1 between the state of FIGS. 15(a) and15(b) and the state of FIGS. 16(a) and 16(b).

[0078] (7) Seventh Step (Wire Feeding Step; FIGS. 17(a) and 17(b) andFIGS. 18(a) and 18(b))

[0079] In a seventh step that is a wire feeding step, the individualcomponents of the winding machine 20 are moved in the same manner as inthe first step shown in FIGS. 5(a) and 5(b) and FIGS. 6(a) and 6(b) andthe fourth step shown in FIGS. 11(a) and 11(b) and FIGS. 12(a) and12(b). While the rotation of the rotary plate 31 continues to besuspended (the state of FIGS. 16(a) and 16(b) is kept), the wire 17 isfed by the feed mechanism 50 in the direction indicated by arrow C so asto trace the supply line. FIGS. 17(a) and 17(b) show a state that thewire 17 has been fed leftward by a length L/2 from the state of FIGS.16(a) and 16(b) so as to trace the supply line, and FIGS. 18(a) and18(b) show a state that the wire 17 has been fed by a length L from thestate of FIGS. 16(a) and 16(b) so as to trace the supply line. FIGS.18(a) and 18(b) show a state that the turning portion 15D has beenadvanced leftward by the length L from the state of FIGS. 16(a) and16(b) and a portion having the length L is set between the turningportion 15D and the shaping gap 36 in plane E-E.

[0080] (8) Eighth Step (Turning Step; FIGS. 19(a) and 19(b) and FIGS.20(a) and 20(b))

[0081] In an eighth step that is a turning step, the individualcomponents of the winding machine 20 are moved in the same manner as inthe second step shown in FIGS. 7(a) and 7(b) and FIGS. 8(a) and 8(b) andthe fifth step shown in FIGS. 13(a) and 13(b) and FIGS. 14(a) and 14(b).The operation of the wire feed mechanism 50 is suspended. The rotaryplate 31 is rotated again in the direction indicated by arrow A1 whilethe wire 17 is gripped by the rollers 51 and 52 being sandwiched betweenthem. FIGS. 19(a) and 19(b) show a state that the shaping roller 35 hasbeen rotated by 90° from the state of FIGS. 18A and 18B, and FIGS. 20Aand 20B show a state the shaping roller 35 has been rotated by 180° fromthe state of FIGS. 18(a) and 18(b) to form the next turning portion 15C.In the eighth step, the next half turn of the intended coil member 15including a straight first portion 15A and a first turning portion 15Cis formed.

[0082] (9) Ninth Step (Pushing Step; FIGS. 21(a) and 21(b) and FIGS.22(a) and 22(b))

[0083] In a ninth step that is a pushing step, the individual componentsof the winding machine 20 are moved in the same manner as in the thirdstep shown in FIGS. 9(a) and 9(b) and FIGS. 10(a) and 10(b) and thesixth step shown in FIGS. 15(a) and 15(b) and FIGS. 16(a) and 16(b). Ina state that the wire 17 is kept gripped by the rollers 51 and 52 beingsandwiched in between, as shown in FIGS. 21(a) and 21(b), the pushingmember 61 is moved in the direction indicated by arrow D1, whereby thestraight first portion 15A is pushed by the prescribed length p so as togo away from the turning base surface 32. In the state of FIGS. 21(a)and 21(b), the shaping roller 35 is held right over the central shaft 33as in the state of FIGS. 20(a) and 20(b). On the other hand, between thestate of FIGS. 21(a) and 21(b) and the state of FIGS. 22(a) and 22(b),the shaping roller 35 is moved (returned) in the direction indicated byarrow A2 until it is located right under the central shaft 33. Alsobetween the state of FIGS. 21(a) and 21(b) and the state of FIGS. 22(a)and 22(b), the pushing member 61 is moved in the direction indicated byarrow D2 and thereby returned to the original position.

[0084] The first to ninth steps of the winding step to form a coilmember 15 have been described above in detail. It is understood from theabove description that the first to third steps (three steps), thefourth to sixth steps (three steps), and the seventh to ninth steps(three steps) constitute respective winding step units. Each windingstep unit includes the wire feeding step that is represented by thefirst, fourth, and seventh steps, the turning step that is representedby the second, fifth, and eighth steps, and the pushing step that isrepresented by the third, sixth, and ninth steps. The individualcomponents of the winding machine 20 are moved in the same manner ineach winding step unit, every time one winding step unit is executed, ahalf turn of the intended coil member 15 is formed and then pushed bythe prescribed length p so as to go away from the turning base surface32. Therefore, by repeatedly executing the winding step unit, half turnsof the intended coil member 15 are formed sequentially. In this manner,a coil member 15 having a necessary number of turns is manufactured.FIG. 23 shows a state that 3.5 turns have been formed by executing thewinding step unit seven times. FIGS. 24(a) and 24(b) are a plan view anda front view, respectively, of a coil member 15 obtained aftercompletion of execution of the winding step.

[0085] According to the manufacturing method of the first embodiment,the length L of each of the straight first portion 15A and the straightsecond portion 15B of a coil member 15 is determined by the length L ofthe feed of the wire 17 by the wire feed mechanism 50 in the first step(FIGS. 5(a) and 5(b) and FIGS. 6(a) and 6(b)), the fourth step (FIGS.11(a) and 11(b) and FIGS. 12(a) and 12(b)), and the seventh step (FIGS.17(a) and 17(b) and FIGS. 18(a) and 18(b)) and hence can easily bechanged by causing the setting element 23 to change the setting value ofthe length L. The pitch P between the first parallel straight portion 15a 1 and the second parallel straight portion 15 b 1 of a coil member 15is determined by the push length p of the pushing member 61 in the thirdstep (FIGS. 9(a) and 9(b) and FIGS. 10(a) and 10(b)), the sixth step(FIGS. 15(a) and 15(b) and FIGS. 16(a) and 16(b)), and the ninth step(FIGS. 21(a) and 21(b) and FIGS. 22(a) and 22(b)) and hence can easilybe changed by causing the setting element 25 to change the setting valueof the length p. In particular, it is possible to change the pitch Ppartially in a single coil combination 12. Further, since the wire 17 isturned on the common turning base surface 32, turning portions can bemade smaller than in the conventional method in which a pair ofplate-like winding cores are rotated.

[0086] The first embodiment can correctly form turning portions that areuniform in shape because first turning portions 15C and second turningportions 15D are formed by using the turning mechanism 30. Since theturning mechanism 30 is provided with the central shaft 33 and theshaping roller 35 that is rotated around the central shaft 33, the wire17 is bent smoothly to form each turning portion. Even if the wire 17 isan insulated wire, there does not occur trouble that the insulationcoating peels off at turning portions. Since the wire 17 is bent throughrotation of the shaping roller 35 at the shaping gap 36 between thecentral shaft 33 and the shaping roller 35, turning portions can easilybe formed. Further, since the shaping roller 35 as well as the centralshaft 33 is provided on the rotary plate 31, the turning mechanism 30can be constructed more easily.

[0087] In the first embodiment, the wire 17 is bent by the turningmechanism 30 in a state that the wire 17 is gripped by the wire feedmechanism 50. The wire 17 is prevented from moving when it is bent, andhence the wire 17 can be bent correctly. The first embodiment employsthe pushing member 61 that is movable in the axial direction of therotary plate 31. The pushing member 61 can easily push a straight firstportion 15A and a straight second portion 15B so that they go away fromthe turning base surface 32. Further, the first embodiment employs therotary plate moving mechanism 39 to move the rotary plate 31 in itsaxial direction. This makes it possible to easily adjust the angle ofturning portions by moving the rotary plate 31 in its axial direction.

[0088] [Embodiments Relating to Manufacturing Method of Coil Assembly 10of Rotary Electric Machine]

[0089] Embodiment 2

[0090] Next, a description will be made of a second embodiment relatingto the manufacturing method of a coil assembly 10 of a rotary electricmachine that has a plurality of coil members 15. In the secondembodiment, a coil assembly 10 is manufactured by using coil members 15manufactured according to the first embodiment. In this manufacturingmethod of a coil assembly 10, a weaving step, a pressing step, adisplacing step, and an inserting step are executed in this order.

[0091] <Weaving Step>

[0092] In the second embodiment, after many coil members 15 shown inFIGS. 24(a) and 24(b) have been manufactured by the winding step, onecoil member 15 is woven into another. The weaving step will be describedbelow with reference to FIGS. 25(a) and 25(b) to FIGS. 30(a) and 30(b)in which FIGS. 25(a), 26(b), . . . , 30(a) are plan views and FIGS.25(b), 26(b), . . . , 30(b) are front views.

[0093] FIGS. 25(a) and 25(b) show an initial state of the weaving step.In the weaving step, one coil member 151 is woven into another coilmember 152. In FIGS. 25(a) and 25(b), the coil member 151 is located onthe left side and the coil member 152 is located on the right side. Thefirst one of the straight first portion 15A from the left of the coilmember 152 is positioned above the first one of the straight secondportion 15B from the right of the coil member 151 so as to cross thelatter. All the turning portions 15C of the coil members 151 and 152 arealigned on the top side, and all the turning portions 15D of the coilmembers 151 and 152 are aligned on the bottom side.

[0094] FIGS. 26(a) and 26(b) show a state that the coil member 152 hasbeen rotated about its coil axis by 90° from the state of FIGS. 25(a)and 25(b) and advanced by a half turn toward the coil member 151. In thestate of FIGS. 26(a) and 26(b), the coil members 151 and 152 are woventogether by one turn. The first one of the straight first portion 15Afrom the left of the coil member 152 is positioned below the first oneof the straight first portion 15A from the right of the coil member 151so as to cross the latter. And the first one of the straight secondportion 15B from the left of the coil member 152 is positioned above thefirst one of the straight second portion 15B from the right of the coilmember 151 so as to cross the latter.

[0095] FIGS. 27(a) and 27(b) show a state that the coil member 152 hasbeen rotated further about its coil axis by 90° from the state of FIGS.26(a) and 26(b). The coil member 152 has not been advanced toward thecoil member 151. The coil members 151 and 152 are woven together by oneturn as in the state of FIGS. 26(a) and 26(b). In the state of FIGS.27(a) and 27(b), whereas the turning portions 15C of the coil member 151are located on the top side, the turning portions 15C of the coil member152 are located on the bottom side, i.e., their turning portions 15C arelocated on the top and bottom sides in the converse relation.

[0096] FIGS. 28(a) and 28(b) show a state that the coil member 152 hasbeen rotated further about its coil axis by 90° from the state of FIGS.27(a) and 27(b) and advanced further by a half turn toward the coilmember 151 from the state of FIGS. 27(a) and 27(b). In the state ofFIGS. 28(a) and 28(b), the coil members 151 and 152 are woven togetherby 1.5 turns. The first one of the straight first portion 15A from theleft of the coil member 152 is positioned above the second one of thestraight second portion 15B from the right of the coil member 151 so asto cross the latter.

[0097] FIGS. 29(a) and 29(b) show a state that the coil member 152 hasbeen rotated further about its coil axis by 90° from the state of FIGS.28(a) and 28(b). The coil member 152 has not been advanced toward thecoil member 151. The coil members 151 and 152 are woven together by 1.5turns as in the state of FIGS. 28(a) and 28(b). In the state of FIGS.29(a) and 29(b), all the turning portions 15C of the coil members 151and 152 are aligned on the top side and all of their turning portions15D are aligned on the bottom side.

[0098] As described above, the coil member 152 is progressively woveninto the coil member 152 by a half turn at a time by repeatedlyexecuting the step of rotating the coil member 152 about its coil axisby 90° and advancing the coil member 152 toward the coil member 151 by ahalf turn so as to increase the overlap between the coil members 151 and152 and the step of rotating the coil member 152 further about its coilaxis by 90°.

[0099] FIGS. 30(a) and 30(b) show a state that the weaving of the coilmember 152 into the coil member 151 has completed. In the state of FIGS.30(a) and 30(b), each straight first portion 15A of the coil member 152is positioned between two adjoining straight first portions 15A of thecoil member 151 in plane E-E and these all straight first portions 15Aare parallel with each other. Each straight second portion 15B of thecoil member 152 is positioned between two adjoining straight secondportions 15B of the coil member 151 in plane F-F and these all straightsecond portions 15B are parallel with each other. Each straight firstportion 15A of the coil member 152 is positioned above the associatedstraight second portion 15B of the coil member 151 so as to cross thelatter, and each straight second portion 15B of the coil member 152 ispositioned below the associated straight first portion 15A of the coilmember 151 so as to cross the latter.

[0100] Further, in the state of FIGS. 30(a) and 30(b), all the turningportions 15C of the coil members 151 and 152 are aligned on the top sideand all of their turning portions 15D are aligned on the bottom side.

[0101]FIG. 31 show a coil assembly 10 in a state that the number ofeleven of other coil members 15 have been woven into one coil member 15.In the state of FIG. 31, all the first portions 15A of the twelve coilmembers 15 are arranged approximately parallel with each other in thefirst plane E-E and all the second portions 15B of the twelve coilmembers 15 are arranged approximately parallel with each other in thesecond plane F-F. The first turning portions 15C are aligned at the topside of the coil assembly 10 and the second turning portions 15D arealigned at the bottom side of the coil member 10.

[0102] <Pressing Step>

[0103] In the second embodiment, the pressing step is executed after theweaving step. In the pressing step, the coil assembly 10 that has beenobtained after completion of the execution of the weaving step ispressed so that the first plane E-E where the straight first portions15A exist and the second plane F-F where the straight second portions15B exist come closer to each other.

[0104] FIGS. 32(A) and 32(B) illustrate how the pressing step isexecuted. FIG. 32(A) is a plan view of the coil assembly 10 that hasbeen obtained after completion of the execution of the weaving step. Thefirst plane E-E where the straight first portions 15A exist and thesecond plane F-F where the straight second portions 15B exist aredistant from and in parallel with each other. As shown FIG. 32(B), atleast one of the straight first portions 15A and the straight secondportions 15B are pressed against the other so as to locate the innercircumferential surfaces of the straight first and the second portions15A and 15B in substantially the same plane, in the pressing step.

[0105] <Displacing Step>

[0106] In the second embodiment, the displacing step is executed on acoil assembly 10 obtained after completion of the execution of thepressing step. In the displacing step, after the pressing step has beenexecuted on the coil assembly 10 shown in FIG. 31. Each coil member 15of the coil assembly 10 is deformed so as to assume a tortoise shellpattern as shown in FIG. 2 and each pair of coil members 15 are combinedand positioned on each other as shown in FIG. 3, whereby a plurality ofcoil combinations 12 are formed.

[0107] In the displacing step, four movable members 80A, 80B, 80C, and80D each having a plurality of pins are used. As shown in FIG. 32C, themovable members 80A and 80C are provided on the side of the straightfirst portions 15A of each coil member 15 and the movable members 80Band 80D are provided on the opposite side, that is, on the side of thestraight second portions 15B of each coil member 15. The movable member80A has a plurality of pins 80 a for simultaneously moving bottomportions 15 ab of the straight first portions 15A of each coil member15, and the movable member 80B has a plurality of pins 80 b forsimultaneously moving bottom portions 15 bb of the straight secondportions 15B of each coil member 15. The movable member 80C has aplurality of pins 80 c for simultaneously moving top portions 15 aa ofthe straight first portions 15A of each coil member 15, and the movablemember 80D has a plurality of pins 80 d for simultaneously moving topportions 15 ba of the straight second portions 15B of each coil member15.

[0108]FIGS. 33 and 34 illustrate how the movable members 80A to 80D aremoved. As shown in FIGS. 33 and 34, the movable member 80A is movedrightward, whereby the bottom portions 15 ab of the straight firstportions 15A are moved rightward by the respective pins 80 a. Themovable member 80B is moved leftward (i.e., in the direction opposite tothe direction in which the movable member 80A is moved), whereby thebottom portions 15 bb of the straight second portions 15B are movedleftward by the respective pins 80 b. The movable member 80C is movedleftward, whereby the top portions 15 aa of the straight first portions15A are moved leftward by the respective pins 80 c. The movable member80D is moved rightward (i.e., in the direction opposite to the directionin which the movable member 80C is moved), whereby the top portions 15ba of the straight second portions 15B are moved rightward by therespective pins 80 d. As a result of the movements of the movablemembers 80A to 80D, each coil member 15 is deformed from a stateindicated by solid lines in FIG. 34 to a state indicated by brokenlines.

[0109] As seen from FIG. 34, the top portion 15 aa of each straightfirst portion 15A that exists in the first plane E-E is moved leftwardand its bottom portion 15 ab is moved rightward, whereby a firstparallel straight portion 15 a 1 and inclined portions 15 a 2 and 15 a 3are formed. The top portion 15 ba of each straight second portion 15Bthat exists in the second plane F-F is moved rightward and its bottomportion 15 bb is moved leftward, whereby a second parallel straightportion 15 b 1 and inclined portions 15 b 2 and 15 b 3 are formed. Inthis manner, a deformed coil member 15 as shown in FIG. 2 is formed.

[0110] Attention is now paid to a relationship between the one coilmember 15 indicated by the solid lines in FIG. 34 and the another coilmember 15 indicated by chain lines. Before execution of the displacingstep, each straight first portion 15A of the another coil member 15indicated by chain lines crosses the associated straight second portion15B of the one coil member 15 indicated by the solid lines at its middlepoint G. After the movable members 80A to 80D have been moved, eachfirst parallel straight portion 15 a 1 of the another coil member 15indicated by the chain lines is positioned in contact with theassociated second parallel straight portion 15 b 1 indicated by thebroken lines at its above. Similarly, before execution of the displacingstep, each straight second portion 15B of the another coil member 15indicated by the chain lines crosses the associated straight firstportion 15A of the one coil member 15 indicated by the solid lines atits middle point G. After the movable members 80A to 80D have beenmoved, each second parallel straight portion 15 b 1 of the another coilmember 15 indicated by the chain lines is positioned in contact with theassociated first parallel straight portion 15 a 1 indicated by thebroken lines, at its below. In this manner, in the displacing step, acoil combination 12 is formed as shown in FIG. 3 in such a manner thatassociated parallel straight portions 15 a 1 and 15 b 1 are laid one onanother.

[0111] <Inserting Step>

[0112] In the second embodiment, an inserting step in which the coilassembly 10 is inserted into the slots of a stator iron core of a rotaryelectric machine is executed after the displacing step. The stator ironcore is developed so as to assume a flat-plate-like shape and its onesurface is formed with a plurality of slots at prescribed intervals. Onepair of parallel straight portions 15 a 1 and 15 b 1, laid one onanother, of a coil combination 12 of the coil assembly 10 are insertedinto one slot as an inner layer and an outer layer, respectively.Typically, in the one slot, the parallel straight portion 15 a 1 isdisposed at its inner layer and the parallel straight portion 15 b 1 isdisposed at its outer layer. Another pair of parallel straight portions15 b 1 and 15 a 1 laid one on another, of the same coil combination 12of the coil assembly 10 are inserted, as an inner layer and an outerlayer, respectively, into another slot having a distance of N slots fromthe one slot. Typically, in the another slot, the parallel straightportion 15 b 1 is disposed at its inner layer and the parallel straightportion 15 a 1 is disposed at its outer layer.

[0113] After all the coil combinations 12 have been inserted into theslots in the above manner, the stator iron core is bent into acylindrical shape so that the slots are located inside and the two endsof the stator iron core are joined to each other. Then, a connectingstep is executed in which necessary internal connections are made forthe coil assembly 10, that is, the ends of the coil members 15 areconnected to each other properly, whereby a stator is completed.

[0114] Although in the above-described second embodiment the pressingstep is executed before the displacing step, the pressing step can beexecuted after the displacing step.

[0115] Also in the manufacturing method of a coil assembly 10 accordingto the second embodiment, the length L of each of the straight firstportion 15A and the straight second portion 15B of each coil member 15is determined by the length L of the feed of the wire 17 by the wirefeed mechanism 50 in the first step (FIGS. 5(a) and 5(b) and FIGS. 6(a)and 6(b)), the fourth step (FIGS. 11(a) and 11(b) and FIGS. 12(a) and12(b)), and the seventh step (FIGS. 17(a) and 17(b) and FIGS. 18(a) and18(b)) and hence can easily be changed by causing the setting element 23to change the setting value of the length L. The pitch P between thefirst parallel straight portion 15 a 1 and the second parallel straightportion 15 b 1 of each coil member 15 is determined by the push length pof the pushing member 61 in the third step (FIGS. 9(a) and 9(b) andFIGS. 10(a) and 10(b)), the sixth step (FIGS. 15(a) and 15(b) and FIGS.16(a) and 16(b)), and the ninth step (FIGS. 21(a) and 21(b) and FIGS.22(a) and 22(b)) and hence can easily be changed by causing the settingelement 25 to change the setting value of the length p. In particular,it is possible to change the pitch P partially in a single coilcombination 12. Further, since the wire 17 is turned on the commonturning base surface 32, turning portions can be made smaller than inthe conventional method in which a pair of plate-like winding cores arerotated.

[0116] According to the second embodiment, a coil assembly 10 can easilybe formed by weaving a plurality of coil members 15 together so thattheir first portions 15A, second portions 15B, first turning portions15C, and second turning portions 15D are each arranged side by side toeach other. In particular, a coil assembly 10 can easily be formed byperforming the weaving after a plurality of coil members 15 have beenformed.

[0117] In the second embodiment, after a plurality of coil member 15have been formed and woven together, the displacing step is executed inwhich a first parallel straight portion 15 a 1 is formed at each firstportion 15A and a second parallel straight portion 15 b 1 is formed ateach second portion 15B. Therefore, the coil members 15 can easily beinserted into the slots in a state that the first parallel straightportions 15 a 1 and the second parallel straight portions 15 b 1 areparallel with each other.

[0118] In the second embodiment, for two coil members 15, the way afirst parallel straight portion 15 a 1 and a second parallel straightportion 15 b 1 that are associated with each other are positioned oneach other in the above or below relationship is changed in thedisplacing step. Therefore, the electrical characteristics of the twocoil members 15 in the slots can be made closer to each other. Inparticular, since the positional relationship between the two coilmembers 15 are changed every turn in such a manner that in a certainslot the first parallel straight portion 15 a 1 of a first coil member15 serves as a first layer and the second parallel straight portion 15 b1 of a second coil member 15 serves as a second layer and that in a slotthat is distant from the certain slot the first parallel straightportion 15 a 1 of the first coil member 15 serves as a second layer andthe second parallel straight portion 15 b 1 of the second coil member 15serves as a first layer. The electrical characteristics can be made evencloser to each other.

[0119] In the second embodiment, the ends of the coil members 15 areconnected to each other after a coil assembly 10 has been inserted intoan iron core. Therefore, insertion work can be performed easily andconnections can easily be made for the coil assembly 10.

[0120] In the second embodiment, the pressing step is executed in whichthe first plane where the first portions 15A of a plurality of coilmembers 15 exist and the second plane where their second portions 15Bare brought closer to each other. This makes it easier to bring firstand second coil members 15 closer to each other in each slot. Inparticular, since the pressing step is executed after the weaving stepand before the displacing step, the displacing step can be executed moreefficiently because the two planes have been made closer to each otherby the pressing step.

[0121] Embodiment 3

[0122] A third embodiment relating to the manufacturing method of a coilassembly of a rotary electric machine according to the invention will bedescribed below with reference to FIG. 35.

[0123] The third embodiment relates to a weaving method in which aftercompletion of execution of the winding step on one coil member 15,another coil member 15 is woven into the one coil member 15 while beingformed by winding the wire 17. In FIG. 35, components and portionshaving the same ones in the first or second embodiment are given thesame reference symbols as the latter.

[0124] In FIG. 35, a coil member 151 that has been obtained by executingthe winding step exists on the left side and another coil member 153exists on the right side. FIG. 35 shows a state that the coil members151 and 153 have been woven together over only 2.5 turns. The first oneof the straight first portion 15A from the left of the coil member 153is positioned above the third one of the straight second portion 15Bfrom the right of the coil member 151 so as to cross the latter. Thefourth one of the straight first portion 15A from the left of the coilmember 153 has just been pushed by the pushing member 61 so as to goaway from the turning base surface 32 by the dimension p.

[0125] In the state of FIG. 35, a wire feeding step of feeding the coilmember 153 upward (in FIG. 35) by the dimension L is executed in thesame manner as in, for example, the fourth step shown in FIGS. 11(a) and11(b) and FIGS. 12(a) and 12(b). Then, a turning step of forming thenext turning portion 15D and second portion 15B by bending the wire 17is executed in the same manner as in, for example, the fifth step shownin FIGS. 13(a) and 13(b) and FIGS. 14(a) and 14(b). Then, a pushing stepof pushing the second portion 15B by the pushing member 61 so that itgoes away from the turning base surface 32 by the dimension p isexecuted in the same manner as in, for example, the sixth step shown inFIGS. 15(a) and 15(b) and FIGS. 16(a) and 16(b). In the turning stepamong the above steps, the coil member 153 is rotated about its coilaxis by 180°, whereby the first one of the straight first portion 15Afrom the left of the coil member 153 is positioned below the straightfirst portion 15A of the coil member 151 so as to cross the latter inthe same manner as shown in FIGS. 27(a) and 27(b). In the ensuingpushing step, the coil member 153 is pushed toward the coil member 151so as to be woven into the coil member 151 further by a half pitch,whereby the first one of the straight first portion 15A from the left ofthe coil member 153 is positioned above the next straight second portion15B of the coil member 151 so as to cross the latter in the same manneras shown in FIGS. 29(a) and 29(b).

[0126] As described above, in the third embodiment, the coil member 153is woven into the coil member 151 progressively while being formed bywinding the wire 17. Therefore, the winding step of forming a coilmember 15 and the weaving step of weaving the same coil member 15 intoanother coil member 15 can be executed simultaneously. This makes itpossible to omit the separate weaving step and thereby simplify theprocess and shorten the work time.

[0127] Embodiment 4

[0128] A fourth embodiment relating to the manufacturing method of acoil assembly of a rotary electric machine according to the inventionwill be described below with reference to FIG. 36. The fourth embodimentrelates to a weaving method in which a plurality of coil members 15 arewoven into other coil members 15 that are already woven together whilebeing formed by winding wires 17. In FIG. 36, components and portionshaving the same ones in the first, second, or third embodiment are giventhe same reference symbols as the latter.

[0129] In FIG. 36, coil members 151 and 152 that have been obtained byexecuting the winding step exist on the left side and other coil members153 and 154 exist on the right side. In FIG. 36, the coil members 151and 152 are already woven together as a result of execution of thewinding step and the weaving step. FIG. 36 shows a state that the coilmembers 153 and 154 have been woven into the coil members 151 and 152only over 2.5 turns. The first ones of the straight first portions 15Afrom the left of the respective coil members 153 and 154 are positionedabove the third ones of the straight second portions 15B from the rightof the respective coil members 151 and 152 so as to cross the latter.The fourth ones of the straight first portions 15A from the left of therespective coil member 153 and 154 have just been pushed by the pushingmember 61 so as to go away from the turning base surface 32 by thedimension p.

[0130] In the state of FIG. 36, a wire feeding step of feeding the coilmembers 153 and 154 upward (in FIG. 36) by the dimension L is executedin the same manner as in, for example, the fourth step shown in FIGS.11(a) and 11(b) and FIGS. 12(a) and 12(b). Then, a turning step offorming the next turning portions 15D and straight second portions 15Bby bending the wires 17 is executed in the same manner as in, forexample, the fifth step shown in FIGS. 13(a) and 13(b) and FIGS. 14(a)and 14(b). Then, a pushing step of pushing the straight second portions15B by the pushing member 61 so that they go away from the turning basesurface 32 by the dimension p is executed in the same manner as in, forexample, the sixth step shown in FIGS. 15(a) and 15(b) and FIGS. 16(a)and 16(b). In the turning step among the above steps, the coil members153 and 154 shown in FIG. 36 are rotated about their coil axis by 180°,whereby their first ones of the straight first portions 15A from theleft of the coil member 153 and 154 are positioned below the straightfirst portions 15A of the coil members 151 and 152 so as to cross thelatter in the same manner as shown in FIGS. 27(a) and 27(b). In theensuing pushing step, the coil members 153 and 154 are pushed toward thecoil members 151 and 152 so as to be woven into the coil members 151 and152 further by a half pitch, whereby the first ones of the straightfirst portions 15A from the left of the coil members 153 and 154 arepositioned above the next second portions 15B of the coil members 151and 152 so as to cross the latter in the same manner as shown in FIGS.29(a) and 29(b).

[0131] As described above, in the fourth embodiment, the coil members153 and 154 are woven into the coil members 151 and 152 progressivelywhile being formed by winding the wires 17. Therefore, the winding stepof forming two coil members 15 and the weaving step of weaving the samecoil members 15 into other coil members 15 can be executedsimultaneously. This makes it possible to omit the separate weaving stepand thereby simplify the process and shorten the work time.

[0132] Although in the fourth embodiment the method for forming the twocoil members 153 and 154 simultaneously by winding the wires 17 has beendescribed with illustration, it is possible to form more number (e.g.,three or four) of coil members 15 while weaving those into other coilmembers 15. Although the fourth embodiment is such that coil members 15are woven into the two coil members 151 and 152 that are already woventogether, the former can be woven into a single coil member 15 or threeor more coil members 15 that are already woven together.

[0133]FIG. 37 shows another coil assembly 10A obtained after completionof execution of the weaving step. The coil assembly 10A is basically thesame as the coil assembly 10 shown in FIG. 31 and is different from thelatter in the structures of end portions of the coil assembly. In thecase of FIG. 31, in the left end portion and the right end portion ofthe coil assembly 10, the end portions of all the twelve coil members 15extend downward. In contrast, in the coil assembly 10A of FIG. 37, thefirst portions 15A, located in the left end portion, of six coil members15 and their second portions 15B located in the right end portion extenddownward. And the second portions 15B, located in the left end portion,of the remaining six coil members 15 and their first portions 15Alocated in the right end portion extend upward. Such a coil assembly 10Acan also be manufactured easily in short time by the method of thefourth embodiment.

[0134] Embodiment 5

[0135] A fifth embodiment relating to the manufacturing method of a coilassembly of a rotary electric machine according to the invention will bedescribed below with reference to FIGS. 38 and 39. The fifth embodimentrelates to another weaving method in which coil members 15 are woveninto another coil member 15 while being formed by winding wires 17. InFIG. 38, components and portions having the same ones in the first,second, third, or fourth embodiment are given the same reference symbolsas the latter.

[0136] As shown in FIG. 38, coil members 152 and 153 are woven, fromboth sides, while being formed by winding wires 17, into a coil member151 that has already been formed by the winding step. Two windingmachines 20A and 20B are used to form the coil members 152 and 153. Thewinding machines 20A and 20B are the same as the winding machine 20 ofFIGS. 4(a) and 4(b) except that they are additionally provided with acoating peeling mechanism 75. The winding machines 20A and 20B areinstalled in such a manner that their turning base surfaces 32 areopposed to each other. In the state of FIG. 38, the coil member 152 hasbeen woven into the coil member 151 from the left by 2.5 turns and thecoil member 153 has been woven into the coil member 151 from the rightby 2.5 turns.

[0137] In each of the winding machines 20A and 20B shown in FIG. 38, thecoating peeling mechanism 75 is provided between the wire feed mechanism50 and the pushing member 61. The coating peeling mechanism 75 peels adesired portion of the insulation coating from the wire 17 bysandwiching that portion between a pair of rollers. In the example ofFIG. 38, coating-peeled portions 15H are formed at the ends of each ofthe coil members 151, 152, and 153 by the coating peeling mechanism 75.In each coating-peeled portion 15H, the insulation coating of the wire17 is peeled off and the internal conductor is exposed. Among thosecoating-peeled portions 15H, the right-end coating-peeled portion 15H ofthe coil member 152 and the left-end coating-peeled portion 15H of thecoil member 153, in particular, are located close to each other at thecenter of the coil member 151, whereby they can easily be connected toeach other there. This structure of coil members is effective in forminga coil assembly 10B shown in FIG. 39. In the coil assembly 10B of FIG.39, a plurality of connection terminals 15J are formed at its centralportion. Each connection terminal 15J is formed by connecting twocoating-peeled portions 15H.

[0138] The fifth embodiment is effective in forming a connectionterminal 15J at the center as in the case of the coil assembly 10B.Further, two coil members 152 and 153 can be woven into another coilmember 151 while being formed by the pair of winding machines 20A and20B by winding wires 17. As such, the fifth embodiment is effective insimplifying the winding step and the weaving step.

[0139]FIG. 38 illustrates the weaving method in which the coil members152 and 153 are woven into the coil member 151 that has been formed bythe winding step from the right and left sides while being formed bywinding the wires 17. Another method is possible in which the coilmember 151 is omitted and the two coil members 152 and 153 are woventogether while being formed by winding the wires 17. In this method, thetwo coil members 152 and 153 can be woven together while being formed bythe two winding machines 20A and 20B. This makes it unnecessary toexecute a separate weaving step.

[0140] [Embodiment Relating to Manufacturing Apparatus of Coil Member ofRotary Electric Machine]

[0141] A sixth embodiment relating to a manufacturing apparatus of acoil member of a rotary electric machine will be described below.

[0142] Embodiment 6

[0143] For convenience of description, the main configuration of thewinding machine 20 has been described above with reference to FIGS. 4(a)and 4(b). The configuration of the winding machine 20 will be describedagain as the sixth embodiment.

[0144]FIG. 40 is a front view showing the configuration of the windingmachine 20. FIG. 41 is a sectional view taken along line A-A in FIG. 40.

[0145] As already described above, the winding machine 20 has theturning mechanism 30, the wire feed mechanism 50, and the pushingmechanism 60. FIGS. 40 and 41 show driving mechanisms therefor togetherwith a case 21. The rotary plate 31 of the turning mechanism 30 isattached to a rotary shaft 40 and driven by a rotational drivingmechanism 37 and a rotary plate moving mechanism 39. The rotary shaft 40penetrates through the case 21, and an electric motor 41 as therotational driving mechanism 37 is provided inside and attached to thecase 21. The electric motor 41 has, on its rotation axis, a gear 42,which is in mesh with a gear 43 that is attached to the rotary shaft 40of the rotary plate 31. The electric motor 41 rotates the rotary plate31 via the gears 42 and 43. The rotary plate 31 is rotated in thedirection indicated by arrow A1 in FIG. 4(b) by rotating the electricmotor 41 in the normal direction and is rotated in the directionindicated by arrow A2 in FIG. 4(b) by rotating the electric motor 41 inthe reverse direction. The rotation angle of the rotary plate 31 can beset by setting the number of rotations of the electric motor 41.

[0146] An electric motor 45 as the rotary plate moving mechanism 39 isalso provided inside and attached to the case 21. The electric motor 45reciprocates the rotary plate 31 along its center axis in the directionsindicated by arrows B1 and B2 in FIG. 4(a). The rotary shaft 40 of therotary plate 31 has a threaded shaft 40 a whose outer circumferentialsurface is threaded. A cylinder 46 is threadedly engaged with thethreaded shaft 40 a. The cylinder 46 is connected, by a belt 47, to acylinder 48 that is attached to the rotary shaft of the electric motor45. Rotational force of the electric motor 45 is transmitted to the belt47 via the cylinder 48, rotates the cylinder 46, and then moves thethreaded shaft 40 a along its axis. As a result, the rotary plate 31 ismoved along its axis. When the motor 45 is rotated in the normal andreverse directions, the rotary plate 31 is reciprocated in thedirections indicated by arrows B1 and B2 in FIG. 4(a). The movementlength is set by setting the number of rotations of the electric motor45.

[0147] Next, the wire feed mechanism 50 will be described. The drivingmechanism for the wire feed mechanism 50 includes an electric motor 55,which is provided inside and attached to the case 21. The electric motor55 rotates the lower feed roller 52 of the pair of feed rollers 51 and52. The feed rollers 51 and 52 are in elastic contact with each otherwith the wire 17 sandwiched in between. The wire 17 can be fed byrotating the one feed roller 52. In a state that the electric motor 55is stopped, the wire 17 is gripped by the feed rollers 51 and 52 beingsandwiched in between and its movement is suspended. The feed roller 52is attached to a rotary shaft 56, which is supported by the case 21 viaa ball bearing 57. The rotary shaft 56 is connected to a rotary shaft 59of the electric motor 55 by a coupler 58.

[0148] The number of rotations of the electric motor 55 determines thefeed length L of the wire 17. The winding step of a coil member 15includes the wire feeding steps (the first step shown in FIGS. 5(a) and5(b) and FIGS. 6(a) and 6(b), the fourth step shown in FIGS. 11(a) and11(b) and FIGS. 12(a) and 12(b), and the seventh step shown in FIGS.17(a) and 17(b) and FIGS. 18(a) and 18(b)). The feed length L of thewire 17 in the direction indicated by arrow C is given. A settingelement 23 sets the feed length L by setting the number of rotations ofthe electric motor 55. The feed length L can easily be changed bychanging the number of rotations of the electric motor 55 by the settingelement 23.

[0149] The pushing mechanism 60 for the pushing member 61 includes anelectric motor 63, which is provided inside and attached to the case 21.As shown in FIGS. 40 and 41, the pushing member 61 has a cut portion 61a for establishing a supply line of the wire 17 and thereby bridges overthe supply line of the wire 17. The pushing member 61 has a pushingsurface 62, which is located on the front face of the supply line of thewire 17. The winding step of a coil member 15 includes the turning steps(the second step shown in FIGS. 7(a) and 7(b) and FIGS. 8(a) and 8(b),the fifth step shown in FIGS. 13(a) and 13(b) and FIGS. 14(a) and 14(b),and the eighth step shown in FIGS. 19(a) and 19(b) and FIGS. 20(a) and20(b)), a first portion 15A and a second portion 15B as well as turningportions 15C and 15D are formed in these turning steps. The firstportion 15A or the second portion 15B is brought out so as to extend toimmediately in front of the pushing surface 62, and is pushed by thepushing member 61 in the ensuing pushing step.

[0150] The pushing member 61 is attached, via a bearing, to a threadedshaft 65 whose outer circumferential surface is threaded, and hence isnot rotated even when the threaded shaft 65 is rotated. The threadedshaft 65 penetrates through the case 21 with a cylinder 66 interposed inbetween, and is connected to a rotary shaft 68 of the electric motor 63via a coupler 67. The internal circumferential surface of the cylinder66 constitutes a threaded hole that is threadedly engaged with thethreaded shaft 65. When rotated, the threaded shaft 65 is moved in itsaxial direction. As the threaded shaft 65 is moved in its axialdirection, the pushing member 61 is moved along the axis of the rotaryplate 31. By rotating the electric motor 63 in the normal and reversedirections, the pushing member 61 is reciprocated in the directionsindicated by arrows D1 and D2 in FIG. 4(a) by the dimension p. The pushdimension p of the pushing member 61 is determined by the number ofrotations of the electric motor 65. A setting element 35 sets the pushdimension p of the pushing member 61 by setting the number of rotationsof the motor 63. The push dimension p can easily be changed by changingthe setting value of the setting element 35.

[0151] The operation of the winding machine 20 shown in FIGS. 40 and 41,which was described above in detail with reference to FIGS. 5(a) and5(b) to FIGS. 22(a) and 22(b), will be summarized below. The followingthree steps, that is, the wire feeding step, the turning step, and thepushing step, are executed in this order repeatedly, whereby a straightfirst portion 15A, a first turning portion 15C, a straight secondportion 15B, and a second turning portion 15D are formed in the wire 17and the straight first portion 15A and the straight second portion 15Bare pushed aside.

[0152] (1) Wire Feeding Step

[0153] The wire feeding step is represented by the first step shown inFIGS. 5(a) and 5(b) and FIGS. 6(a) and 6(b), the fourth step shown inFIGS. 11(a) and 11(b) and FIGS. 12(a) and 12(b), and the seventh stepshown in FIGS. 17(a) and 17(b) and FIGS. 18(a) and 18(b). In the wirefeeding step, all of the operation that the electric motor 41 rotatesthe rotary plate 31, the operation that the electric motor 45reciprocates the rotary plate 31 in its axial direction, and theoperation that the electric motor 63 pushes the pushing member 61 aresuspended. In this state, the electric motor 55 drives the feed roller52 of the wire feed mechanism 50, whereby the wire 17 is fed, throughthe shaping gap 36, in the direction indicated by arrow C by thedimension L that is set by the setting element 23.

[0154] This operation sets a portion having the length L to become astraight first portion 15A or a straight second portion 15B.

[0155] (2) Turning Step

[0156] The turning step is represented by the second step shown in FIGS.7(a) and 7(b) and FIGS. 8(a) and 8(b), the fifth step shown in FIGS.13(a) and 13(b) and FIGS. 14(a) and 14(b), and the eighth step shown inFIGS. 19(a) and 19(b) and FIGS. 20(a) and 20(b). In the turning step,the feed of the wire 17 by the electric motor 55 (wire feed mechanism50) is suspended and the wire 17 is gripped by the feed rollers 51 and52 being sandwiched in between. The operation that the electric motor 63pushes the pushing member 61 is also suspended. In this state, theoperation that the electric motor 41 rotates the rotary plate 31 and theoperation that the electric motor 45 reciprocates the rotary plate 31 inits axial direction are performed.

[0157] Driven by the electric motor 41, first the rotary plate 31 isrotated in the direction indicated by arrow A1 and the shaping roller 35is rotated about the central shaft 33, whereby the wire 17 is bent atthe shaping gap 36 on the turning base surface 32. As a result, a firstturning portion 15C or a second turning portion 15D is formed. At thesame time, accompanying the formation of the first turning portion 15Cand the second turning portion 15D, a straight first portion 15A or astraight second portion 15B is formed for which the length L was set inthe preceding wire feeding step. After the formation of the firstturning portion 15C or the second turning portion 15D, the rotary plate31 is driven by the electric motor 41 so as to rotate in the directionindicated by arrow A2 and is thereby returned to the original position.

[0158] During the above operation, the electric motor 45 reciprocatesthe rotary plate 31 in the directions indicated by arrows B1 and B2(axial direction), whereby the angle of the turning portion 15C or 15Dis adjusted.

[0159] (3) Pushing Step

[0160] Pushing step is represented by the third step shown in FIGS. 9(a)and 9(b) and FIGS. 10(a) and 10(b), the sixth step shown in FIGS. 15(a)and 15(b) and FIGS. 16(a) and 16(b), and the ninth step shown in FIGS.21(a) and 21(b) and FIGS. 22(a) and 22(b). In the pushing step, both ofthe operation that the electric motor 41 rotates the rotary plate 31 andthe operation that the electric motor 45 reciprocates the rotary plate31 in the axial direction are suspended. The wire feeding operation bythe electric motor 55 is also suspended, and hence the wire 17 isgripped by the feed rollers 51 and 52 being sandwiched in between. Inthis state, driven by the electric motor 63, the pushing member 61 isreciprocated in the directions indicated by arrows D1 and D2 (axialdirection of the rotary plate 31), whereby the straight first portion15A or the straight second portion 15B is pushed in the axial directionof the rotary plate 31 by the prescribed dimension p that is set by thesetting element 25 so as to go away from the turning base surface 32.

[0161] The coating peeling mechanism 75 is added to the wiring machine20 if necessary. The coating peeling mechanism 75 is disposed on thewire supply line between the wire feed mechanism 50 and the pushingmember 61 and attached to the case 21. The coating peeling mechanism 75is used for forming coating-peeled portions 15H in the wire 17 atnecessary positions. For example, the coating peeling mechanism 75 isused effective for forming connection terminals 15J in a coil assemblyas shown in FIGS. 38 and 39.

[0162] According to the winding machine 20 of the sixth embodiment, thelength L of each of the straight first portion 15A and the straightsecond portion 15B can easily be changed by changing the setting lengthL of the setting element 23. The push pitch p of the straight firstportion 15A or the straight second portion 15B can also be changedeasily by changing the setting value p of the setting element 25. Inaddition, the push pitch p can easily be changed partially even duringformation of a coil member 15.

[0163] In the winding machine 20 of FIGS. 40 and 41, the central shaft33 as well as the shaping roller 35 is attached to the rotary plate 31.Therefore, the attachment structures of the central shaft 33 and theshaping roller 35 are simplified, and the dimension of the shaping gap36 between the central shaft 33 and the shaping roller 35 is keptconstant, which makes it possible to form a coil member 15 morecorrectly.

[0164] In the winding machine 20, each of a first turning portion 15C ora second turning portion 15D is formed in a state that the wire 17 isgripped by the wire feed mechanism 50. Therefore, the turning portions15C and 15D can be formed more reliably and correctly. Further, sincethe rotary plate moving mechanism 39 is provided to move the rotaryplate 31 in its axial direction, the inclination of each of the turningportions 15C and 15D can easily be adjusted. In the case where thecoating peeling mechanism 75 is provided, coating-peeled portions 15Hcan easily be formed in a coil member 15 at prescribed positions andintermediate connection terminals 15J, for example, can easily beformed.

[0165] [Rotary Electric Machine Using Coil Assembly According to theInvention]

[0166]FIG. 42 is a sectional view of an exemplary rotary electricmachine using a coil assembly 10, 10A, or 10B that has been manufacturedaccording to the invention.

[0167] This rotary electric machine is an AC generator that is mountedon a vehicle, and is used for charging a battery of the vehicle,supplying power to various electric loads on the vehicle, and otherpurposes. The AC generator has a rotary shaft 101, a pair of brackets110 and 111, a rotor 120, and a stator 130. The rotor 120 has a pair ofrotor iron cores 121 and 122 and a rotary coil 123. Being a field coil,the rotary coil 123 is excited by a pair of brushes 102 and 103 and sliprings 104 and 105 that are provided on the rotary shaft 101. The rotaryshaft 101 is supported by the pair of brackets 110, 111 via bearings 112and 113.

[0168] The stator 130 has an annular stator iron core 131 and a coilassembly 10 that are provided around the rotor 120. The innercircumferential surface of the stator iron core 131 is formed with a lotof slots at prescribed intervals, and coil combinations 12 of the coilassembly 10 are inserted in the slots. More specifically, associatedfirst and second parallel straight portions 15 a 1 and 15 b 1 of therespective coil members 15 of each coil combination 12 are inserted inthe same slot. The coil assembly 10 serves as an output coil of the ACgenerator. When the rotary shaft 101 is driven by an engine or the like,the generator generates an AC voltage, which is converted by arectifier, for example, into a DC voltage, which is supplied to thebattery and the various electric loads.

What is claimed is:
 1. A manufacturing method of a coil member of arotary electric machine including a winding step of forming a firstturning portion, a straight portion, and a second turning portion in atleast one wire, the winding step comprising: a step of settingprescribed dimensions L and p; a first turning step of forming the firstturning portion by turning the wire on a turning base surface; a wirefeeding step of advancing the wire by the prescribed dimension L afterthe first turning step; a second turning step of turning, after the wirefeeding step, the wire on the turning base surface in the same directionas the wire was turned in forming the first turning portion, to therebyform the second turning portion and form the straight portion betweenthe first turning portion and the second turning portion; and a pushingstep of pushing, after the second turning step, the straight portion sothat the straight portion goes away from the turning base surface by theprescribed dimension p.
 2. The manufacturing method according to claim1, wherein the first turning portion and the second turning portion areformed before and after the wire feeding step, respectively, by using aturning mechanism.
 3. The manufacturing method according to claim 2,wherein the turning mechanism comprises a central shaft and a shapingroller that rotates around the central shaft, and wherein the firstturning portion and the second turning portion are formed by turning thewire by rotation of the shaping roller at a shaping gap that is formedbetween the central shaft and the shaping roller.
 4. The manufacturingmethod according to claim 2, wherein the turning mechanism comprises arotary plate having the turning base surface, a central shaft that isprovided at a rotation center of the rotary plate perpendicularly to theturning base surface, and a shaping roller that is attached to therotary plate perpendicularly to the turning base surface and rotatesaround the central shaft, and wherein the first turning portion and thesecond turning portion are formed by turning the wire by rotation of theshaping roller at a shaping gap that is formed between the central shaftand the shaping roller.
 5. The manufacturing method according to claim4, wherein the central shaft is also attached to the rotary plate androtates together with the rotary plate.
 6. The manufacturing methodaccording to claim 2, wherein a wire feed mechanism for feeding the wireis used, the wire feed mechanism comprising a pair of feed rollers forsandwiching the wire in between, and wherein the turning mechanism turnsthe wire in a state that the wire is gripped by the feed rollers.
 7. Themanufacturing method according to claim 4, wherein the straight portionis pushed away from the turning base surface by a pushing member that ismovable along an axis of the rotary plate.
 8. The manufacturing methodaccording to claim 4, wherein inclinations of the first turning portionand the second turning portion are adjusted by a rotary plate movingmechanism for moving the rotary plate along its axis.
 9. A manufacturingmethod of a coil assembly of a rotary electric machine in which the coilassembly includes a plurality of coil members each of which is formed bya winding step of winding a wire so as to form a plurality of firstportions, a plurality of second portions, a plurality of first turningportions each of which connects one of the first portions and one of thesecond portions that is located on one side of and adjacent to the oneof first portions, and a plurality of second turning portions each ofwhich connects one of the first portions and one of the second portionsthat is located on the other side of and adjacent to the one of firstportions, the winding step comprising: a step of setting prescribeddimensions L and p; a first wire feeding step of feeding the wire tothereby set the length L for one of the first portions based on theprescribed dimension L; a first turning step of turning, after the firstwire feeding step, the wire on a turning base surface to thereby formone of the first turning portions and one of the first portions; a firstpushing step of pushing, after the first turning step, the one of firstportions so that the one of first portions goes away from the turningbase surface by the prescribed dimension p; a second wire feeding stepof feeding, after the first pushing step, the wire to thereby set thelength L for one of the second portions based on a the prescribed lengthL; a second turning step of turning, after the second wire feeding step,the wire on the turning base surface in the same direction as the wirewas turned in forming the one of first turning portions, to thereby formone of the second turning portions and form one of the second portionsbetween the one of first turning portions and the one of second turningportions; and a second pushing step of pushing, after the second turningstep, the one of second portions so that the one of second portions goesaway from the turning base surface by the prescribed dimension p. 10.The manufacturing method according to claim 9, wherein at least firstone of the coil members and second one of the coil members are woventogether so that the first portions, the second portions, the firstturning portions and the second turning portions of the first one of thecoil members are respectively arranged side by side with the firstportions, the second portions, the first turning portions and the secondturning portions of the second one of the coil members.
 11. Themanufacturing method according to claim 10, wherein the first one andthe second one of the coil members are formed by repeatedly executingthe winding step, and are then woven together.
 12. The manufacturingmethod according to claim 10, wherein the second one of the coil membersis woven, while being formed by executing the winding step, into thefirst one of the coil members that has been formed by executing thewinding step.
 13. The manufacturing method according to claim 10,wherein the first one and the second one of the coil members are woventogether while being formed simultaneously by executing the windingstep.
 14. The manufacturing method according to claim 10, wherein thefirst one of the coil members and the second one of the coil members areformed on two respective turning base surfaces that are opposed to eachother so as to be pushed toward each other, and are woven together. 15.The manufacturing method according to claim 10, wherein the first one ofthe coil members and the second one of the coil members are formed ontwo respective turning base surfaces that are opposed to each other soas to be pushed toward each other, and are woven into another coilmember that has been formed by executing the winding step.
 16. Themanufacturing method according to claim 15, wherein the wires for thefirst one, the second one and the another of the coil members areinsulated wires, and wherein insulation coatings are peeled from theinsulated wires at prescribed positions while the first one and thesecond one of the coil members are formed on the turning base surfaces,to enable formation of connection terminals in the insulated wires. 17.The manufacturing method according to claim 10, further comprising adisplacing step of displacing the coil members after the coil membershave been formed by winding the wires and woven together, wherein in thedisplacing step, first end portions of the respective first portions andfirst end portions of the respective second portions of each of thefirst one and the second one of the coil members are displaced inopposite directions, and second end portions of the respective firstportions and second end portions of the respective second portions ofeach of the first one and the second one of coil members are displacedin opposite directions, whereby first parallel straight portions areformed at the respective first portions and second parallel straightportions are formed at the respective second portions.
 18. Themanufacturing method according to claim 17, wherein in the displacingstep, a plurality of coil combinations are formed each of which is acombination of the first one and the second one of the coil members, andeach of the plurality of coil combinations is such that the secondparallel straight portions of the second one of coil members are incontact with, from below, the first parallel straight portions of thefirst one of the coil members, respectively, and that the first parallelstraight portions of the second one of the coil members are in contactwith, from above, the second parallel straight portions of the first oneof the coil members, respectively.
 19. The manufacturing methodaccording to claim 18, further comprising an inserting step of insertingthe coil assembly into slots of an iron core after the displacing step,wherein in the inserting step, each of the plurality of coilcombinations are inserted into the slots that are formed in the ironcore at a prescribed pitch in such a manner that each of the firstparallel straight portions of the first one of the coil members and eachof the second parallel straight portions of the second one of the coilmembers are inserted into a prescribed slot as a first layer and asecond layer, respectively, and each of the first parallel straightportions of the second one of the coil members and each of the secondparallel straight portions of the first one of the coil members areinserted into a slot that is distant from the prescribed slot by aprescribed number of pitches as a first layer and a second layer,respectively.
 20. The manufacturing method according to claim 19,further comprising a connecting step of connecting ends of the coilmembers after the inserting step.
 21. The manufacturing method accordingto claim 17, further comprising a pressing step of pressing the coilmembers so that a first plane where the first portions exist and asecond plane where the second portions exist come closer to each other.22. The manufacturing method according to claim 21, wherein the pressingstep is executed after weaving the coil members together and before thedisplacing step.
 23. A manufacturing apparatus for a coil member of arotary electric machine having first turning portions, straightportions, and second turning portions, comprising: a rotary plate havinga turning base surface on which winding of a wire is performed; a firstmotor for rotating the rotary plate intermittently about an axisthereof; a central shaft that is provided perpendicularly to the turningbase surface on the axis of the rotary plate; a shaping roller that isattached to the rotary plate perpendicularly to the turning basesurface, is opposed to the central shaft with a shaping gap formed inbetween, and rotates around the central shaft; a wire feed mechanism forfeeding the wire through the shaping gap; a second motor for driving thewire feed mechanism intermittently; a first setting element for settinga dimension L of the wire feed by the driving of the second motor; apushing member that is movable along the axis of the rotary plate; athird motor for driving the pushing member intermittently; and a secondsetting element for setting a dimension p of a push of the pushingmember by the driving of the third motor, wherein the manufacturingapparatus executes the steps of: causing the first motor to turn thewire on the turning base surface to thereby form one of the firstturning portions; causing, after forming the one of first turningportions, the second motor to advance the wire by the dimension L thatis set by the first setting element; causing, after advancing the wire,the first motor to turn the wire on the turning base surface in the samedirection as the wire was turned in forming the one of first turningportions, to thereby form one of the second turning portions and formone of the straight portions between the one of first turning portionsand the one of second turning portions; and causing, after forming theone of second turning portions, the third motor to move the pushingmember so as to push the one of straight portions so that the one ofstraight portions goes away from the turning base surface by thedimension p.
 24. The manufacturing apparatus according to claim 23,wherein the central shaft is also attached to the rotary plate androtates together with the rotary plate.
 25. The manufacturing apparatusaccording to claim 23, wherein the one of first turning portions and theone of second turning portions are formed by rotation of the rotaryplate in a state that the wire is gripped by the wire feed mechanism.26. The manufacturing apparatus according to claim 23, furthercomprising a rotary plate moving mechanism for moving the rotary platealong its axis, wherein inclinations of the one of first turningportions and the one of second turning portions are adjusted by therotary plate moving mechanism.
 27. The manufacturing apparatus accordingto claim 23, wherein the wire is an insulated wire, and wherein themanufacturing apparatus further comprises a peeling mechanism forpeeling an insulation coating from the insulated wire at prescribedpositions.